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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Transporter, Caravelle (1990 release)

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Volkswagen Transporter / Caravelle
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Volkswagen
Transporter / Caravelle
Instructions
Engine
General Data Engine
Removing and installing engine
Removing radiator
Removal and installation of a mudguard of the engine
Toothed belt
Adjusting the timing belt
Removing and installing toothed belt
4-cylinder petrol engine
4-cylinder diesel engine
5-cylinder petrol engine
5-cylinder diesel engine
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Removing and installing the camshaft
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Replacing valve stem seals
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Compression Test
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4-cylinder petrol engine



2.5.2.1. 4-cylinder petrol engine

Withdrawal

PERFORMANCE ORDER
1. Remove the V-belt (see. Subsection 2.12.1).
2. Install the crankshaft to TDC for cylinder 1 and more provision is not changed.

Installing the engine to TDC for cylinder 1

PERFORMANCE ORDER
1. Remove the top casing of a gear belt.
2. Remove the plug on the clutch housing.
3. Turn the motor shaft to align the TDC mark.
4. The rotation of the motor shaft can be done in different ways:
- Lift one end of the car so that the wheel is free and upon enabling the transfer of 5, rotate the front wheel;
- Set the machine on a flat surface. Enable transfer 5. Push the car forward or backward;
- To establish a transmission in neutral position. Tighten the hand brake. Remove the bottom mudguard of the engine. Rotate the crankshaft at central bolt damper.

A warning

Do not turn the engine over a cam bolt, it can lead to an overload of the toothed belt.


5. The motor rotates as long as the camshaft does not take a position for 1 cylinder TDC. If the label on a cam drive gear should coincide with a label on the casing of a gear belt. There are 2 versions (indicated by the arrow A and the arrow B).
6. If the label on a flywheel (0) or the clutch plate must coincide with TDC. Otherwise, continue to rotate the crankshaft.
7. Disconnect the damper to the crankshaft.
8. Remove the top and bottom casing of a gear belt.
9. Loosen and remove the timing belt.

Setting

PERFORMANCE ORDER
1. Check TDC position of camshaft, crankshaft and intermediate shaft, if necessary, install it.
2. Check the position of the camshaft at TDC of the first cylinder. The label on a cam drive gear in this case coincides with the mark on the casing of a gear belt. If necessary, carefully turn the camshaft at the removed gear belt.

A warning

If you want to turn the camshaft at the removed gear belt, no one piston should be at TDC. For this purpose, apply the color bar on the damper and rotate the crankshaft 90 ?� forward or back. Finally, if the cam was set to TDC for cylinder 1, set crankshaft to TDC again for 1 cylinder. To rotate the crankshaft vibration damper is used.


3. Simultaneously, the crankshaft should be in TDC position. In this case, the mark on the flywheel or the clutch plate must coincide with TDC.
4. At the same time mark on runner distributor should coincide with a label on the edge of the timing case. Otherwise crank respectively idler. In order to make this check, remove the ignition distributor, to remove the slider distributor, remove the dust cap, and finally, again, set the slider.
5. Check the simultaneous coincidence of all three labels. In this case, the engine is at TDC for cylinder one.
6. Put the toothed belt on the wheel of the crankshaft, camshaft drive gear and idler gear.

A warning

When installing the toothed belt can not change the position of the camshaft, crankshaft and intermediate shaft. Failure to do so could result in severe damage to the engine or the engine will not develop full power.

After the tension once again check the position of the camshaft, an intermediate shaft and a belt pulley. This means that when the mark on the camshaft drive gear coincides with the corresponding mark on the casing of a gear belt, at the same time must coincide with the mark on the flywheel with the mark on the ignition distributor. Otherwise, repeat the installation at the removed gear belt.


7. Screw the vibration damper.
8. Tighten the timing belt.
9. Double Crank in the direction of rotation of the engine and re-check the adjustment.
10. Remove the vibration damper.
11. To establish the bottom casing of a gear belt.
12. Install the top casing of a gear belt.
13. Install the vibration damper and tighten to 25 Nm.
14. Install the dust cap, and then the ignition distributor.
15. Install and tighten the V-belt (see. Subsection 2.12.1).
16. Check the ignition timing and adjust if necessary.

A warning

At repair that requires removal of the timing belt only with the drive gear camshaft adjustment of the toothed belt to produce the manner described below.


17. Mark on the camshaft drive gear must coincide with the mark on the cylinder head cover.
18. Loosen and remove the toothed belt camshaft drive gear.

A warning

Camshaft and intermediate shaft no longer be changed.


19. Push and pull the toothed belt.
20. Remove the ignition distributor. Check the installation of the distributor and runner label.
21. Crank 2 turns and check the alignment of the camshaft and crankshaft marks.
22. Check the ignition timing and adjust if necessary (see. Subsection 2.14.6).
23. Run the engine. If the timing belt whistles, it will draw.




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